Aerosol Generating Device and an Aerosol Generating System

ABSTRACT

An aerosol generating device having a housing comprises a first aerosol generating unit and a chamber. The first aerosol generating unit is adapted to generate a first type of vapor from a solid substrate. The first aerosol generating unit further comprises a receiving interface for a consumable. The interface includes a plurality of heating elements with spikes that are arranged such that they are inserted into the consumable when the consumable is received by the interface. At least a part of the interface is arranged in the chamber of the housing. The spikes of the heating elements are arranged in at least two arrays and the opposing arrays of heating elements with spikes are configured to heat uniformly a region of the consumable between the opposing arrays.

The present invention relates to an aerosol generating device and an aerosol generating system according to the preamble of the independent claims.

Aerosol generating devices and systems have the ability to generate an aerosol as the result of heat generated by electrical power sources. The aerosol is intended to be drawn into the mouth of a user. Of particular interest are aerosol delivery devices and systems that provide components of tobacco in an aerosol form, such as is provided by devices commonly known as electronic cigarettes. As used herein, the term aerosol is meant to include vapors, gases, aerosols, and/or particulate matter of form or type suitable for human inhalation, whether visible or not, and whether or not of the form that might be considered to be smoke like.

One example of an aerosol generation device is described in US 2018/0056015 A1l. US 2018/0056015 A1 discloses a dual vaporizer having a vaporizing assembly with a first chamber with plant matter for holding dry plant matter. The dry plant matter is heated with a first heating element. Additionally, the dual vaporizer includes a second chamber with a second heating element, in which a wick that is in fluid communication with the second chamber draws a liquid. The wick is heated with a coil to generate a vapor.

Another aerosol generation device is shown in CN 103 431 525 B. The device includes a housing with a tobacco column assembly. The assembly includes heating pins that are arranged in a column. However, the heating pins only penetrate a peripheral region of an inserted consumable. As a result, during operation, a peripheral part of the consumable is heated to a different temperature than an inner part of the consumable, resulting in either the periphery or the inner part not being sufficiently heated or being heated to too high temperatures, which may result in an unpleasant taste.

The problem of the invention is thus providing an aerosol with a smooth taste that is pleasant to the consumer.

According to an aspect of the invention, an aerosol generating device with a housing is provided. The aerosol generating device comprises a first aerosol generating unit. The first aerosol generating unit is adapted to generate the first type of vapor from a solid substrate. The first aerosol generating unit further comprises a receiving interface for a consumable. The interface includes a plurality of heating elements with spikes that are arranged such that they are inserted into the consumable when the consumable is received by the interface. The interface may comprise a temperature sensor, that is adapted to be inserted into the consumable.

In a preferred embodiment, the housing includes a chamber in which at least a part of the interface is arranged. The spikes of the heating elements are arranged in at least two arrays. An array may be understood as a regular or irregular arrangement of the heating elements. For example, the heating elements may be arranged in a column (i.e. a 1 by X array) or in multiple columns (i.e. an 2, 3 or 4 by X array). The spacing between the heating element in column may be regular, in particular identical. The columns may extend along the same direction. A spacing between the columns may be regular, in particular identical. Each array may have a width of 2, 3 or 4 columns, wherein each column may have a length of 4, 6, 8 or more heating elements.

By providing the spikes of the heating elements in the above arrays, the consumable comprising a solid substrate is heated more evenly. This provides a reliable and constant quantity and quality of released vapor.

Further, the opposing arrays of heating elements with spikes may be configured to heat a region of the consumable between the opposing arrays uniformly. A uniform heat distribution has the effect of generating smoke uniformly over the entire heated region and leads to an aerosol that is smoother in taste. Further, the entire solid substrate between the arrays may be heated to the right temperature leading to a higher efficiency.

The spikes of one array may have length of at least a quarter, preferably at least a third, or at least half the distance between opposing arrays. The distance between the opposing arrays is in particular a direction of extension of the chamber. For example, the chamber may be a cylinder with a circular base having a diameter (e.g. 30 mm). In this case the distance between opposing arrays may be 30 mm (or less) and the spikes have a length of at least 7.5 mm, 10 mm or 15 mm. Preferably, the spikes of both opposing arrays have a length of at least a quarter, preferably at least a third, or at least half the distance between opposing arrays.

In a further aspect of the invention, the aerosol generating device may comprise a second aerosol generating unit adapted to generate a second type of vapor from a liquid substrate. Further, the first aerosol generating unit may be arranged upstream or downstream of the second aerosol generating unit with regard to the airflow through the aerosol generating device during normal operation by the user.

Both variations (upstream and downstream) may improve the quality of the released vapor.

Surprisingly, it has been found that the combination of the heating elements with spikes and the upstream arrangement of the first aerosol generating unit leads to a smoother aerosol and a user experience is significantly improved due to more enriched flavor as compared to the known devices.

In preferred embodiments, the heating elements themselves may form the spikes. For example, the heating elements may be formed by resistive wires that are bent to form a sharp tip. In further embodiments, the spikes are made of a susceptor material at least partially and heated by a magnetic coil or the spikes are covered by a resistively heatable material or spikes are at least partially made of a resistively heatable material.

In particular embodiments, the chamber may comprise 2, 3, 4 or more arrays.

In a preferred embodiment, the chamber has a cylindrical shape and a central axis. The at least two arrays may extend in the direction of the central axis or in the direction of a circumference of the cylindrical shape. Thereby, a uniform heating of the consumable is provided. Note that the arrays may extend along the same direction or in different directions from each other. The arrays may be arranged around a circumference of the cylindrical chamber.

In a preferred embodiment, the spikes extend along an axial or radial direction of the chamber. In particular, when the heating elements are arranged at an end portion of the cylindrical chamber, they extend along the axial direction of the chamber and when the heating elements are arranged on the curved surface of the cylinder, they extend in the radial direction.

In a preferred embodiment the spikes of the at least two arrays are arranged at generally opposing sides of the chamber such that the consumable can be held at the interface by the spikes. When the spikes are arranged at generally opposing sides, the consumable is fixed securely in the chamber and an accidental release is avoided. In addition, the heating within the consumable is particularly uniform.

In a preferred embodiment the spikes on generally opposing sides of the chamber connect to each other to form a closed circuit. In this way, heating penetration through the core of the consumable is ensured.

In a preferred embodiment, the housing comprises a closure for the chamber, wherein at least one of the arrays of heating element extends from the closure into the chamber. The closure holds the consumable securely within the chamber. The heating elements, in particular the spikes, extending from the closure fixate the consumable within the interface in a desired position, in which the heat is applied. Thereby, a reliable placement of the consumable within the interface is secured.

Particularly preferred, the closure is a door that may be hinged. Alternatively, the door may also by slidable or separable from the housing or any other suitable mechanism to move the door may be used. A hinged door has the advantage, that pressure to insert the spikes into the consumable can be easily applied.

In a preferred embodiment the at least two arrays extend from opposing sides of the chamber into the chamber and the arrays are offset to one another. For example, one of the arrays may be offset in the axial or circumferential direction of the chamber with respect to the other array. Thereby, a more even heat distribution is achieved and the space within the consumable is used more efficiently.

In a particular embodiment the consumable may be a tobacco stick.

In a particularly preferred embodiment, the spikes overlap at least partly. For example, the spikes may extend from opposing sides of the consumable and may overlap with regard to a direction of extension of one of the arrays. Thereby, a deeper penetration of the spikes into the consumable is allowed and even more spikes can be fitted into the same length of tobacco stick. Further, the solid substrate may be heated more evenly. The opposing spikes may extend along the same direction.

In a preferred embodiment, the interface comprises a temperature sensor. The temperature sensor is adapted to be inserted into the consumable. Preferably, the sensor is a thermocouple and further preferred arranged in a position in a downstream direction of the interface along a direction of airflow. The temperature sensor may be adapted to measure a temperature at a center of the consumable. The temperature sensor may form a spike or maybe inserted through a spike. The spike of the temperature sensor may form a part of one of the previously mentioned arrays or may be arranged separately therefrom. Further preferred, the temperature sensor is arranged at the downstream end of the interface along the direction of airflow.

The temperature sensor can measure a temperature and thus a condition of the tobacco, in particular at the center of the consumable. Thereby, a constant temperature and composition of a provided tobacco vapour is provided. In one example, the temperature sensor can be used for a closed-loop control of the tobacco and vapor temperature control. The closed-loop may include the temperature sensor, a controller, and the heating elements. Thereby, an active monitoring of the core of the tobacco portion in the consumable is enabled so that control is optimized.

In a preferred embodiment, the device comprises a controller, and at least parts of the heating elements are independently controllable by the controller. As a result, the tobacco could be heated from a first end to a second end, similarly to burning a cigarette. Alternatively or additionally, consumables may comprise different tobacco compositions that need to be heated to different temperatures might be provided. For example, in case the consumable is not uniformly packed, the heating energy could be adjusted to the density of different sections of the consumable.

In a preferred embodiment, the chamber includes a first heating zone and a second heating zone. Each of the heating zones comprises one or more heating elements wherein the controller is configured to control the heating elements independently of each other. Defining heating zones may allow for individually adjustable consumables. For example, one of the heating zones may be switched on or off depending on a user's taste or users input. The consumable may include only section in which particular additives such as methanol as additive and a user may decide whether the particular additive is to be consumed. Further, the heating zones may allow a partial consummation of a consumable for later continuation. In case only the solid material in the first heating zone is consumed during a first usage session, a user may switch the device at a later time on and start consuming the solid material in the second heating zone, wherein the user experience will be similar to a new consumable.

In a preferred embodiment the spikes of the heating elements may include an air duct. The air duct may be configured to allow an airflow through the spikes and into the consumable. Thereby, an airflow is directed into the center of the tobacco stick and the air is heated through the spikes upon entry. As a result, more flavors and aromas of the consumable are released.

In a preferred embodiment the first and second aerosol generation units are connected with an airflow passage and the second aerosol generating unit includes a second unit inlet for receiving the first type of vapor through the airflow passage. There may be no inlet in the housing for providing airflow directly to the second aerosol generating unit without passing through the first aerosol generating unit. Thereby the entire airflow passing through the second aerosol generating unit is forced to pass through the first aerosol generating unit.

In a preferred embodiment, the spikes are configured to pierce through a wall of the consumable, when the consumable is received by the interface. Thereby, the consumable may be provided with a wall that isolates the solid substrate from the environment, preserving the solid substrate.

In a preferred embodiment, the device comprises an outlet vapor channel located downstream of the first and second vapor generating units such that the first and second types of vapor are fully mixed before reaching an outlet of the aerosol generating device.

A further aspect of the invention relates to an aerosol generating system comprising an aerosol generating device as outlined above and a consumable. The consumable may comprise a solid substrate. In a preferred embodiment, the system comprises a liquid substrate. In one embodiment only one of the substrates, preferably the solid substrate contains nicotine.

Non-limiting embodiments of the invention are described, by way of example only, with respect to the accompanying drawings, in which:

FIG. 1 : discloses a schematic drawing of an aerosol generation system according to the invention,

FIG. 2 : discloses a detailed view of a first embodiment of an interface for a consumable of the aerosol generation system,

FIG. 3A: discloses a detailed view of a second embodiment of an interface for a consumable of the aerosol generation system,

FIG. 3B: discloses a detailed view of an embodiment of the first aerosol generation unit,

FIG. 4 : discloses a detailed view of a third embodiment of an interface for a consumable of the aerosol generation system,

FIG. 5 : discloses a detailed view of a fourth embodiment of an interface for a consumable of the aerosol generation system, and

FIG. 6 : discloses a detailed view of a fifth embodiment of an interface for a consumable of the aerosol generation system.

FIG. 1 discloses a schematic drawing of an aerosol generation system according to the invention. The aerosol generation system comprises an aerosol generation device 1. The aerosol generation device 1 may receive one or more consumables 30 containing a liquid and/or a solid. The aerosol generation system is then formed by the aerosol generation device 1 in combination with the consumable(s) containing liquid and/or solid.

The aerosol generation device 1 includes a housing 2 that has a generally longitudinal shape. In particular, the housing 2 is cylindrically shaped around central axis 5 and includes a first end 43 and a second end 45. For example, the aerosol generation device 1 may be circular cylindrical. Within the housing 2, a reusable section 40, a first aerosol generation unit 10 and a second aerosol generation unit 20 are arranged. Air enters into the housing through an inlet that is arranged at the first end 43. Alternatively, the inlet may be provided anywhere along the reusable section 40 or at an end of the first aerosol generation unit to facing the first end 43. Generally, the air then flows through the aerosol generation device 1 along a direction of airflow 18 and exits the aerosol generation device through an outlet 44. In the particular embodiment shown in FIG. 1 , the outlet 45 is positioned at the second end.

When the air flows through the aerosol generation device 1, a first type of vapor is added to the airflow by the first aerosol generation unit 10 and a second type of vapor is added to the airflow by the second aerosol generation unit 20.

The reusable section 40 comprises a battery 42 and a controller 8 (see FIG. 2 ). The aerosol generation units 10, 20 and the reusable section 40 may be separable from each other such that they can be individually replaced.

The second aerosol generation unit 20 includes a liquid reservoir comprising a liquid substrate 22. The liquid substrate 22 may include a polyhydric alcohol such as glycerin and propylene glycol, and typically contain no nicotine. Alternatively, the liquid substrate 22 may contain a nicotine component originated from a tobacco material. The liquid substrate 22 may also include a flavorant such as menthol. The liquid comprised in the liquid reservoir is drawn towards a heater 25 by means of a wick 24. The heater 25 is wound around the wick 24 and causes the liquid drawn by the wick from the liquid substrate 22 to evaporate, thereby forming a second type of vapor. The second type of vapor is directed through a conduit 26 towards the outlet 44 of the aerosol generation device 1.

The first aerosol generation unit 10 is arranged at an upstream position with regard to the airflow 18 compared to the second aerosol generation unit 20. The first aerosol generation unit 10 includes a receiving interface 14 for the consumable 30. The consumable includes a solid substrate 32. The substrate may include a tobacco material in various forms such as shredded tobacco and granulated tobacco, and/or the tobacco material may include tobacco leaf and/or reconstituted tobacco. The receiving interface 14 is formed by a chamber 4 in the housing 2. Within the chamber 4, a plurality of heating elements 16 are arranged. The heating elements 16 include spikes 17. The spikes 17 may be entirely or partially formed of an inductively heatable susceptor material. In this case, the aerosol generation device also includes an inductive heating coil for generating an electromagnetic field for heating the susceptor material.

Alternatively, the spikes may include a resistive material, that heats up when an electrical current is guided through the spike from the battery 8. For example, the spikes may be formed by bending a resistive wire to form a sharp tip or the spikes may be covered by a conductive layer of resistive and conductive material. Exemplary embodiments of a suitable heating elements and spikes are shown in the patent documents CN 103431525 B, CN 208676371 U, and CN 104026740 B.

As shown in FIG. 1 , the spikes 17 are arranged in two arrays 12 at opposite sides 7 of the receiving interface 14. The arrays 12 each include a regularly spaced column of 4spikes (i.e. a 1×4 array).

One particularly preferred embodiment of the first aerosol generation unit 10 is shown in FIG. 2 . Each of the heating elements 16 that include the spikes 17 is connected to the controller 8 and the battery 42 (see FIG. 1 ). The heating elements 16 are grouped together in 3 sections: section A, section B and section C. Each of the sections includes 2 sets of opposing heating elements 16 and can be controlled separately from the other sections by the controller 8. When a consumable 30 is inserted into the chamber 4, the heating elements are pushed through a wall of the consumable 30 and into the solid substrate 32 within the consumable 30. This configuration shown in FIG. 2 .

When a smoker begins to consume consumable 30, first only the heating elements 16 disposed in section A are heated. When the solid substrate (e.g. a humectant disposed in the part of the consumable pierced by the heating elements 16 grouped in section A) runs low in section A, the temperature in the heating elements 16 of section A is reduced. Thereafter, a temperature of heating elements 16 in section B is increased, until the solid substrate in the consumable in the area of section B is depleted. Similarly, then, the heating elements in section C are heated up. Thereby, a smoke generated by the consumable is more consistent over the lifetime of the consumable 30. The shown example of FIG. 2 the controller groups the heating elements into 3 sections. However, the heating elements may also be grouped into six sections of opposing heating elements or 2 sections of opposing heating elements. Further, the shown rows of heating elements maybe longer and the sections may also each include 1, 3 or more sets of opposing heating elements.

A further preferred embodiment of heating elements 16 according to the invention is shown in FIG. 3A. The embodiment of FIG. 3A, the heating elements are electrically heatable and are formed by a resistive material of heating elements. For example, the spikes 17 may be at least partially formed by the resistive material or covered by such a resistive heating material. Suitable resistive heating materials should have a sufficient electrical resistance for generating a suitable operating temperature (i.e. about 150° C. to 350° C.), a melting point well above the operating temperature necessary for evaporating the first type of vapor, and a sufficient temperature strength. Example materials are carbon (e.g. graphite) and metallic alloys, such as nickel alloys, molybdenum alloys or tungsten alloys. In some embodiments, or silicon carbide ceramics may also be 3o suitable.

In the embodiment of FIG. 3A, an electrical circuit including the resistive heating elements is only formed, when opposing heating elements 16 connect to each other within the consumable 30. The consumable 30 is inserted into the chamber and then, the heating elements 16 pierce a wall of the consumable and are pushed through the substrate of the consumable 30 until they connect. Then, a current 11 can flow through two opposing heating element 16. During the insertion of the consumable, the heating elements 16 pierce through the core of the consumable (e.g. a tobacco stick). Thereby, a substantially uniform heating of the consumable 30 is insured. Further, the heating element can only be actuated, if the heating elements are properly positioned and mal functions can be avoided.

In one example (see FIG. 3B), the chamber 4 of the aerosol generation unit 10 may include a hinged door 52. The chamber 4 is opened, by pivoting the door 52 around one or more pivots 51 (e.g. formed by hinges). When the doors open as shown in FIG. 3B, a consumable 30 may be inserted into chamber 4 and then, the door 52 is closed. While the door is closed, the spikes 17 of the door 52 and the spikes 17 in the chamber 4 are pushed into the consumable and penetrate the substrate of the consumable.

In alternative embodiments, the spikes 17 may be movable, for example by a motor, such that they penetrate the consumable after the chamber is closed. In a further alternative embodiment, the door may be slidable or separable from the aerosol generation unit 10.

A further preferred embodiment of the interface is shown in FIG. 4 . Similarly to the embodiment shown in FIG. 2 , the spikes 17 are arranged in two opposing rows of 6 regularly spaced spikes each. As can be seen in FIG. 4 , the opposing rows of spikes are offset by a distance 34 in the direction of the axis 31 of the consumable. Since the opposing rows of spikes are offset to one another, the heat within the consumable is distributed more evenly. Further, due to the offset 34, the spikes 17 can penetrate deeper into the consumable 30 and even overlap by a distance 33 with regard to a radial direction of the consumable or the aerosol generation device.

Another embodiment of the interface is shown in FIG. 5 . The heating elements 16 shown by FIG. 5 may be similar to the heating elements provided in the previous embodiments. In addition, the heating element 16 shown in FIG. 5 include a hollow bore 19, through which the airflow is directed. The hollow bore 19 may be in the center of the heating elements 16. As indicated by arrows 13, air is directly guided into a center portion of the consumable 30 by the bores 13. Since the air is guided through the heating elements with spikes 17, the air is heated while being guided into the consumable 30. The heated air leads to a release of more flavor from the solid substrate.

A further variation of the interface 14 is shown in FIG. 6 showing a fifth embodiment of the interface. In principle, the embodiment shown in FIG. 6 is similar to the embodiment shown in FIG. 2 . Differing from the embodiment shown in FIG. 2 , one of the spikes 17 does not include a heating element 16. In the particular example of FIG. 6 , a spike 17′ that is arranged on a downstream end of one of the arrays 12 and includes an embedded temperature sensor 15, in particular a thermocouple. The temperature sensor 15 is inserted through the spike and arranged at a center of the consumable 30. This means that the thermocouple can measure the tobacco and airflow right at the center of the tobacco. The temperature sensor 15 can be arranged at any place along the direction of airflow. Preferably however, the temperature sensor 15 is placed at the end of the interface 14 in the direction of airflow 18. The addition of such a temperature sensor 15 or thermocouple may allow a closed-loop tobacco or vapor temperature control and an active monitoring of the core of the tobacco portion so that control is optimized. A spike with a temperature sensor 15 or a similar arrangement, wherein the temperature sensor 15 is inserted into the consumable 30 may be provided with any of the arrays 12 provided in the embodiments above. 

1. An aerosol generating device having a housing, comprising: a first aerosol generating unit adapted to generate a first type of vapor, from a solid substrate, the first aerosol generating unit comprising a receiving interface for a consumable, wherein the receiving interface comprises a plurality of heating elements including spikes arranged such that the spikes are inserted into the consumable when the consumable is received by the receiving interface, and a chamber in which at least a part of the receiving interface is arranged and in which the spikes of the heating elements are arranged in at least two arrays, and wherein the at least two arrays of the spikes of the heating elements are configured to heat a region of the consumable therebetween, and wherein the spikes at generally opposing sides of the chamber connect to each other to form a closed circuit.
 2. The aerosol generating device according to claim 1, wherein the chamber has a cylindrical shape and a central axis, and wherein the at least two arrays extend along a direction of the central axis or along a direction of a circumference of the cylindrical shape.
 3. The aerosol generating device according to claim 2, wherein the spikes extend along an axial or radial direction of the chamber.
 4. The aerosol generating device according to claim 1, wherein the spikes of the at least two arrays are arranged at the generally opposing sides of the chamber such that the consumable can be held in the receiving interface by the spikes.
 5. The aerosol generating device according to claim 1, wherein the spikes of the at least two arrays extend into the chamber from the generally opposing sides of the chamber, and wherein the at least two arrays are offset relative to one another.
 6. The aerosol generating device according to claim 5, wherein the spikes at least partly overlap.
 7. Aerosol generating device according to claim 1, wherein the receiving interface comprises a temperature sensor, and wherein the temperature sensor is adapted to be inserted into the consumable.
 8. The aerosol generating device according to claim 1, further comprising a controller, wherein at least portions of the heating elements are independently controllable by the controller.
 9. The aerosol generating device according to claim 8, wherein the chamber includes a first heating zone and a second heating zone, each comprising one or more of the heating elements, and wherein the controller is configured to control the first and second heating zones independently of each other.
 10. The aerosol generating device according to claim 1, wherein the spikes of the heating elements include an air duct configured to allow an airflow through the spikes into the consumable.
 11. The aerosol generating device according to claim 12, wherein the first and second aerosol generating units are connected by an air flow passage, wherein the second aerosol generating unit includes a second unit inlet for receiving the first type of vapor through the air flow passage, and wherein there is no inlet in the housing for providing air flow into the second aerosol generating unit without passing through the first aerosol generating unit.
 12. The aerosol generating device according to claim 1, further comprising a second aerosol generating unit adapted to generate a second type of vapor, from a liquid substrate, wherein the first aerosol generating unit is arranged upstream or downstream of the second aerosol generating unit with respect to a direction of airflow through the aerosol generating device during normal operation by the user.
 13. An aerosol generating system comprising: the aerosol generating device according to claim 1; and the consumable, wherein the consumable comprises the solid substrate.
 14. The aerosol generating system according to claim 13, further comprising a liquid substrate, wherein only one of the solid substrate and the liquid substrate contains nicotine
 15. The aerosol generating system according to claim 14, wherein the solid substrate contains nicotine.
 16. The aerosol generating device according to claim 7, wherein the temperature sensor is a thermocouple.
 17. The aerosol generating device according to claim 7, wherein the temperature sensor is arranged at a downstream end of the receiving interface along a direction of airflow. 